Battery cables with welding wire? - Jeep Wrangler Forum
Jeep Wrangler Forum

Go Back   Jeep Wrangler Forum > TJ Jeep Wrangler Forum > TJ General Discussion Forum

Join Wrangler Forum Today


Reply
 
Thread Tools

Please support our sponsors and let them know you heard about them on WranglerForum.com
Old 10-13-2011, 03:00 AM   #1
Jeeper
 
alamike's Avatar
 
Join Date: Dec 2010
Location: Grass Valley, California
Posts: 60
Battery cables with welding wire?

1997 Wrangler, Sahara edition, 4.0L.

My battery cables are shot and the jeep dealership in the closest town wants $100 for a set. I've got some wire laying around for my Lincoln MIG welder and read somewhere that you could make a set using this welding wire and a few pieces from the hardware store. Could anyone explain if this is possible and how to do it? I need to replace all of it: terminals, the connector to the starter and fuse box, ground, etc. Thanks guys!

__________________
'97 Sahara TJ
-4.0L manual on 35's
-4" Teraflex lift, 4.56 gears
-Dana 30 w/ OX locker up front, Dana 35 w/Detroit in the rear (for now)
alamike is offline   Quote Quick Reply
Old 10-13-2011, 06:12 AM   #2
Jeeper
 
Join Date: Sep 2011
Location: Delaware
Posts: 178
I have never made up cables for my jeep, but have done this in the past with other vehicles. The hardest part for you would be finding the right ends and having access to the crimper needed to put them on properly.

This guy makes a killer set, a little more than $100, but SO much better than stock..
Jeep Wrangler cables

Hammond_Egger is offline   Quote Quick Reply
Old 10-13-2011, 06:15 AM   #3
Jeeper
 
banks316's Avatar
 
Join Date: Apr 2011
Location: Longview, WA
Posts: 2,089
Auto part store less then 50$.
__________________
93 YJ I6 5spd
My YJ Build +1.5 inch SOA ,37 12.50 15R Swamper M16's, 5.22:1/2.97:1 Stak Tcase with 92 Crawl Ratio--------SOLD...
banks316 is online now   Quote Quick Reply
Old 10-13-2011, 06:35 AM   #4
Jeeper
 
Garlandxj's Avatar
 
Join Date: Jun 2011
Location: Garland
Posts: 171
I did this on my 2001 Cherokee. Real easy. Take the measurement of each cable

Battery to Starter
Battery to Power Distribution Center
Alternator to Power Distribution Center
Alternator to Battery

Battery to Chassis Ground
Battery to Block Ground
Block to Firewall Ground (Crappy metal mesh wire at the back of the engine)

2 Marine Terminal to attach to the battery (They have wing nut post for attaching the the cables.

Measure the Size of the bolts at the Chassis, PDC, Starter, Engine Block (Both side and back ground connections), and Fire Wall.

Take measurements and corrorsponding bolt sizes down to your local welding supply store. Have them make the measure lengths of cable and attach the appropriate size ends and crimp them.

Get some colored heat shrink tubing to place over the ends of the positive cables for easy identification.

You also need a In-line fuse between the alternator and the PDC. The fuse needs to be rated close to the max output of your alt to prevent too much amprage going into the PDC.

Hook it all up and have a ball.
Garlandxj is offline   Quote Quick Reply
Old 10-13-2011, 06:38 AM   #5
Commercial Member

WF Supporting Member
 
kfdjason7620's Avatar
 
Join Date: Apr 2011
Location: Kenly, NC
Posts: 3,962
Or you can solder the ends on, or that's what I did to all of em on my golf cart
kfdjason7620 is offline   Quote Quick Reply
Old 10-13-2011, 09:13 AM   #6
Jeeper
 
jgorm's Avatar
 
Join Date: May 2010
Location: San Diego
Posts: 1,841
I would use at least 6 gauge. If I did it on my jeep i'd probably use 0 gauge. Welding wire is usually very high quality wire, just be sure that it's the right gauge.
__________________
my 06 LJ rubicon
2.5" SL, 1" BL, DIY highline, 35s with double beadlocks.
jgorm is offline   Quote Quick Reply
Old 10-13-2011, 10:41 AM   #7
Knows a couple things...

WF Supporting Member
 
Jerry Bransford's Avatar
 
Join Date: Nov 2005
Location: Escondido, Calif.
Posts: 31,060
Images: 2
Yep welding wire is usually fine-strand copper cable which is higher quality than typical battery cables. No problem using that if you use the right gauge of wiring. I'd probably go for 2 gauge.

__________________
When you have a choice, buy American.

Jerry Bransford is online now   Quote Quick Reply
Reply

Quick Reply
Message:
Options

Register Now

In order to be able to post messages on the Jeep Wrangler Forum forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.
User Name:
If you do not want to register, fill this field only and the name will be used as user name for your post.
Password
Please enter a password for your user account. Note that passwords are case-sensitive.
Password:
Confirm Password:
Email Address
Please enter a valid email address for yourself.
Email Address:

Log-in

Human Verification

In order to verify that you are a human and not a spam bot, please enter the answer into the following box below based on the instructions contained in the graphic.



Thread Tools

Posting Rules
You may post new threads
You may post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are Off
Pingbacks are Off
Refbacks are Off


Similar Threads
Thread Thread Starter Forum Replies Last Post
Auxillary Lighting Install Writeup erickpl General Jeep FAQ/Stickies 15 09-20-2013 09:28 AM
88 4.2 v6 wont start flipflop YJ Tech Forum 9 10-16-2012 09:18 AM
Auxilary Lighting Writeup erickpl TJ Tech Forum 2 01-06-2011 07:50 PM
trouble starting. need help! vdog313 YJ Tech Forum 4 09-18-2010 01:23 PM
takin doors off akfisherman TJ General Discussion Forum 12 03-16-2006 09:24 PM


logo carid shop wrangler parts carid fender flares custom wheels store avs deflectors at carid
» Rates
Get low rates on auto insurance in Canada!

» Network Links
»Jeep Parts
» Featured Product

All times are GMT -5. The time now is 07:02 PM.



Jeep®, Wrangler, Liberty, Wagoneer, Cherokee, and Grand Cherokee are copyrighted and trademarked to Chrysler Motors LLC.
Wranglerforum.com is not in any way associated with the Chrysler Motors LLC